Vehicle wheel bearing

ABSTRACT

A first vehicle wheel bearing has a monolithic shaft including two inner races and has a monolithic outer race assembly. A second bearing has a monolithic shaft including a shoulder and at least one inner race, wherein the shaft is positioned within the bore of a vehicle knuckle member with the shoulder abutting the knuckle. A third bearing has an end cap attached to an outer race assembly and covering the bearing-cavity outboard opening. A fourth bearing has an inboard seal covering the bearing-cavity inboard opening and extending outside the cavity to define a target ring for an ABS speed sensor. A fifth bearing has an ABS speed sensor positioned in the bearing cavity and attached to a shaft proximate the outboard opening and has a target ring positioned in the bearing cavity and attached to the outer race assembly.

TECHNICAL FIELD

The present invention relates generally to vehicles, and moreparticularly to a vehicle wheel bearing.

BACKGROUND OF THE INVENTION

Vehicles include automotive vehicles having wheel bearings such as thewheel bearing 10 shown in a below-centerline, cross-sectional view inprior art FIG. 1. The bearing 10 includes the outer race assembly 12having studs 14 to which a wheel (not shown) is attached. The bearing 10also includes outboard and inboard inner races 16 and 18, balls 20 and21 and outboard and inboard seals 22 and 24. These separate pieces areassembled together into a greased unit. A shaft 26 is pressed into thebore 28 of a knuckle member 30 (only a portion of which is shown) fromthe inboard side 32 until a shoulder 34 of the shaft 26 abuts aninboard-facing surface 36 of the knuckle member 30. Then, the bearing 10is pressed onto the shaft 26 and against an outboard-facing surface 38of the knuckle member 30. Finally, a retention nut 40 is threaded onto athreaded end of the shaft 26. An anti-lock-braking-system (ABS) speedsensor 42 is attached to the knuckle member 30 and senses the rotationof a target ring 44 attached to the rotating outer race assembly 12. Theretention nut 40 has the potential to loosen which can lead to reducedbearing life, bearing noise, and ABS speed sensor 42 failure. Althoughthe bearing components are protected from the wheel environment by theoutboard and inboard seals 22 and 24, the ABS speed sensor 42 and thetarget ring 44 are not and require separate protection from the wheelenvironment. The prior art bearing 10 of FIG. 1 is relatively costly tomanufacture, assemble into a unit, and attach to the knuckle member 30.

What is needed is an improved vehicle wheel bearing.

SUMMARY OF THE INVENTION

A first expression of a first embodiment of the invention is for avehicle wheel bearing having a vehicle-wheel-bearing monolithic shaftand a vehicle-wheel-bearing monolithic outer race assembly. The shaftincludes an inboard inner race and an outboard inner race. The outerrace assembly surrounds the shaft and includes an outboard outer raceand an inboard outer race.

A second expression of a first embodiment of the invention is for avehicle wheel bearing having a vehicle-wheel-bearing monolithic,non-rotatable shaft and a vehicle-wheel-bearing monolithic, rotatableouter race assembly. The shaft is attachable to a vehicle suspensioncomponent and includes an inboard inner race and an outboard inner race.The outer race assembly is attachable to a vehicle wheel, surrounds theshaft, and includes an outboard outer race and an inboard outer race.

A third expression of a first embodiment of the invention is for avehicle wheel bearing assembly including a vehicle knuckle member and avehicle wheel bearing. The vehicle knuckle member has a bore and has asubstantially-outboard-facing surface and a substantially-inboard-facingsurface. The vehicle wheel bearing has a monolithic, non-rotatableshaft, an inboard inner race, and a monolithic, rotatable outer raceassembly. The shaft includes an outboard inner race and a shoulder. Theshaft is located in and circumferentially contacts the bore. Theshoulder abuts the substantially-outboard-facing surface. The shaft isattached to the vehicle knuckle member against thesubstantially-inboard-facing surface. The outer race assembly surroundsthe shaft and includes an outboard outer race and an inboard outer race.In one example, the shaft and the inboard inner race define a monolithicstructure. In the same or a different design, the shaft has a deformedportion which abuts the substantially-inboard-facing surface.

A first expression of a second embodiment of the invention is for avehicle wheel bearing including a vehicle-wheel-bearing shaft having aninner race, including a vehicle-wheel-bearing outer race assembly havingan outer race, and including an end cap. The outer race assembly ispositioned radially outwardly apart from the shaft creating a bearingcavity. The bearing cavity has a substantially-circular outboardopening. The end cap is attached to the outer race assembly and has aportion covering the outboard opening, wherein the portion is at leastpartially disposed in the bearing cavity, and wherein the portion has asubstantially toroidal shape.

A second expression of a second embodiment of the invention is for avehicle wheel bearing including a vehicle-wheel-bearing non-rotatableshaft having an inner race, including a vehicle-wheel-bearing rotatableouter race assembly including an outer race, and including an inboardseal. The outer race assembly is positioned radially outwardly apartfrom the shaft creating a bearing cavity. The bearing cavity has asubstantially-circular inboard opening. The inboard seal has a memberattached to the outer race assembly, wherein the member has a firstportion substantially covering the inboard opening and has a secondportion extending radially outwardly of the outer race assembly. Thesecond portion defines a target ring for an anti-lock-braking-systemspeed sensor.

A first expression of a third embodiment of the invention is for avehicle wheel bearing including a vehicle-wheel-bearing non-rotatableshaft having an inner race, including a vehicle-wheel-bearing rotatableouter race assembly having an outer race, including ananti-lock-braking-system (ABS) speed sensor, and including a targetring. The outer race assembly is positioned radially outwardly apartfrom the shaft creating a bearing cavity. The bearing cavity has asubstantially-circular outboard opening. The ABS speed sensor ispositioned in the bearing cavity and is attached to the shaft proximatethe outboard opening. The target ring is positioned in the bearingcavity, is attached to the outer race, and has a portion located to besensed by the ABS speed sensor.

Several benefits and advantages are derived from one or more of theexpressions and embodiments of the invention. Having a monolithic shaftwith inboard and outboard inner races and having a monolithic outer raceassembly with inboard and outboard outer races reduces manufacturingcosts. Having a monolithic shaft with an outboard inner race, ashoulder, and a deformed portion, wherein the shoulder abuts theoutboard-facing surface of the vehicle knuckle member and wherein thedeformed portion abuts the inboard-facing surface of the knuckle membersecures the bearing to the knuckle member without using a retention nutwhich can loosen leading to reduced bearing life, bearing noise, and ABSspeed sensor failure. Having an outboard end cap with a toroidal portionin the bearing cavity allows the toroidal portion to act as a safetyretention ring when arcuate finger-type ball separators are used in thebearing cavity thus integrating sealing and safety retention functionsinto a single member reducing costs. Having an inboard seal extendoutside the bearing cavity to also function as a target ring for an ABSspeed sensor integrates sealing and target ring features into a singlemember reducing costs. Having an ABS speed sensor positioned in thebearing cavity and attached to the shaft proximate the outboard openingof the cavity and having the target ring positioned in the bearingcavity and attached to the outer race assembly places the ABS speedsensor and target ring inside the bearing where an existing bearing sealor end cap offers protection from the wheel environment without the needfor a separate seal for the ABS speed sensor and target ring.

SUMMARY OF THE DRAWINGS

FIG. 1 is a below-centerline, cross-sectional view of a prior artvehicle wheel bearing and vehicle knuckle member;

FIG. 2 is an above-centerline, cross-sectional view of a firstembodiment of a vehicle wheel bearing of the invention and a vehicleknuckle member;

FIG. 3 is a view of an inboard portion of FIG. 2 showing theinboard-facing surface of the knuckle member and a portion of the shaftbefore that portion is deformed to abut the inboard-facing surface ofthe knuckle member;

FIG. 4 is an above-centerline, cross-sectional view of a secondembodiment of a vehicle wheel bearing of the invention and a vehicleknuckle member; and

FIG. 5 is an above-centerline and partially-below-centerline,cross-sectional view of a third embodiment of a vehicle wheel bearing ofthe invention and a vehicle knuckle member.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, FIG. 2 illustrates a first embodiment ofthe present invention. A first expression of the first embodiment is fora vehicle wheel bearing 46 including a vehicle-wheel-bearing monolithicshaft 48 and a vehicle-wheel-bearing monolithic outer race assembly 50.Examples of wheeled vehicles having wheel bearings include, withoutlimitation, automobiles and trucks. The shaft 48 includes an inboardinner race 52 and an outboard inner race 54. The outer race assembly 50surrounds the shaft 48 and includes an outboard outer race 56 and aninboard outer race 58. Thus, the inboard inner race 52, the outboardinner race 54, and other portions of the shaft 48 define a monolithicstructure. Likewise, the outboard outer race 56, the inboard outer race58, and other portions of the outer race assembly 50 define a monolithicstructure. Monolithically integrating the inner races 52 and 54 with theshaft 48 saves manufacturing costs.

A second expression of the first embodiment shown in FIG. 2 is for avehicle wheel bearing 46 including a vehicle-wheel-bearing monolithic,non-rotatable monolithic shaft 48 and a vehicle-wheel-bearingmonolithic, rotatable outer race assembly 50. The shaft 48 is attachableto a vehicle suspension component (such as but not limited to a vehicleknuckle member 60, wherein for purposes of describing the invention, thevehicle knuckle member 60 is considered part of the vehicle suspensionsystem). The shaft 48 includes an inboard inner race 52 and an outboardinner race 54. The outer race assembly 50 is attachable to a vehiclewheel (not shown) such as, without limitation, by having the vehiclewheel be mounted on wheel studs 62 attached to the outer race assembly50. The outer race assembly 50 surrounds the shaft 48 and includes anoutboard outer race 56 and an inboard outer race 58.

A third expression of the first embodiment shown in FIG. 2 is for avehicle wheel bearing assembly 64 including a vehicle knuckle member 60,and a vehicle wheel bearing 46. As previously mentioned, the vehicleknuckle member 60 is considered part of the vehicle suspension systemfor purposes of describing the invention and is connected to othervehicle suspension components, not shown, as is known to those skilledin the art. The vehicle knuckle member 60 has a bore 66 and has asubstantially-outboard-facing surface 68 and asubstantially-inboard-facing surface 70. The vehicle wheel bearing 46includes a monolithic, non-rotatable monolithic shaft 48, an inboardinner race 52, and a monolithic, rotatable outer race assembly 50. Theshaft 48 includes an outboard inner race 54 and a shoulder 72. The shaft48 is disposed in the bore 66. The shoulder 72 abuts thesubstantially-outboard-facing surface 68. The shaft 48 is attached tothe vehicle knuckle member 60 against the substantially-inboard-facingsurface 70. The outer race assembly 50 surrounds the shaft 48 andincludes an outboard outer race 56 and an inboard outer race 58.

In one example of the third expression, the shaft 48 circumferentiallycontacts the wall of the bore 66 such as with a press-fit. In oneconstruction, the shaft 48 and the inboard inner race 52 define amonolithic structure as shown in FIG. 2. In another construction, notshown in FIG. 2, shaft 48 and the inboard inner race 52 are separatemembers. In this other construction, the shaft 48 monolithicallyincludes the outboard inner race 54 but does not monolithically includethe inboard inner race 52.

In one implementation of the third expression, the shaft 48 has adeformed portion 74 which abuts the substantially-inboard-facing surface70 of the vehicle knuckle member 60. The shoulder 72 and the deformedportion 74 of the shaft 48 abuttingly secure the shaft 48 (and hence theentire vehicle wheel bearing 46) to the vehicle knuckle member 60without the use of a retention nut which could loosen leading to reducedbearing life, bearing noise, and ABS speed sensor failure. Beforedeformation, in one construction, the inboard end of the shaft 48 has aledge shape as shown in FIG. 3.

In one design of the third expression, the outboard inner and outerraces 54 and 56 define an outboard raceway containing rolling elementssuch as, but not limited to, balls 76. Likewise, in this design, theinboard inner and outer races 52 and 58 define an inboard racewaycontaining rolling elements such as, but not limited to, balls 78. Inone modification, not shown, an outboard annular separator ring havingdimples to hold and separate the balls 76 is disposed in the outboardraceway, and an inboard annular separator ring having dimples to holdand separate the balls 78 is disposed in the inboard raceway. In onevariation not shown, each annular separator ring is replaced with aplurality of arcuate separators each having radially-inwardly-extendingfingers to separate the balls. The use of annular separator rings and/orarcuate separators is known to the artisan.

In one modification of the third expression, the vehicle wheel bearing46 also includes an inboard seal 80 and further includes an outboard endcap 82 which is attached to a radially-inward-facing surface of theouter race assembly 50 and which sealingly extends to the outer raceassembly 50. It is noted that in this modification, the outboard end cap82 is less expensive to use than a conventional outboard seal. In onevariation, a target ring 84 is attached to a radially-outwardly-facingsurface of the outer race assembly 50 to be sensed by an ABS speedsensor 86 attached to the vehicle knuckle member 60.

During assembly of the vehicle wheel bearing 46, it may be necessary touse a “Conrad”-type assembly, as is known in the art, where, instead ofthe balls being placed in the dimples of an annular separator beforeenclosure by a separate race, the balls are first placed betweenopposing races and then an arcuate finger-type separator is insertedinto the raceway. In one assembly method for the vehicle wheel bearingassembly 64 shown in FIG. 2., the greased and assembled vehicle wheelbearing 46 is brought as a unit (including at least the shaft 48, theouter race assembly 50, the balls 76 and 78, the inboard seal 80, andthe outboard end cap 82) to the area of the vehicle knuckle member 60.The shaft 48 is press fit from the outboard side 87 into the bore 66 ofthe vehicle knuckle member 60 with the shoulder 72 of the shaft 48abutting the outboard-facing surface 68 of the vehicle knuckle member60. Then the inboard end of the shaft 48 seen in FIG. 3 is rolled by atool (not shown) and deformed into the deformed portion 74 seen in FIG.2.

A second embodiment of the invention is shown in FIG. 4. A firstdepiction of the second embodiment shown in FIG. 4 is for a vehiclewheel bearing assembly 88 and is identical to the previously describedthird expression of the first embodiment except for the way the inboardend of the shaft 90 is attached to the vehicle knuckle member 92. In thefirst depiction of the second embodiment, the vehicle wheel bearingassembly 88 also includes a retention nut 94. The shaft 90 has athreaded end 96, and the retention nut 94 is threadably attached to thethreaded end 96 and abuts the substantially-inboard-facing surface 98 ofthe vehicle knuckle member 92.

A first expression of the second embodiment shown in FIG. 4 is for avehicle wheel bearing 100 including a vehicle-wheel-bearing shaft 90, avehicle-wheel-bearing outer race assembly 102, and an end cap 104. Theshaft 90 has an inner race 106 and 108. The outer race assembly 102 hasan outer race 110 and 112 and is disposed radially outwardly apart fromthe shaft 90 creating a bearing cavity 114, wherein the bearing cavity114 has a substantially-circular outboard opening 116. The end cap 104is attached to the outer race assembly 102 and has a portion 118covering the outboard opening 116. The portion 118 is at least partiallydisposed in the bearing cavity 114, and the portion 118 has asubstantially toroidal shape. Having an end cap 104 with a toroidalportion 118 in the bearing cavity 114 allows the toroidal portion 118 toact as a safety retention ring when arcuate finger-type ball separatorsare used in the bearing cavity thus integrating sealing and safetyretention functions into a single member reducing costs.

A second expression of the second embodiment shown in FIG. 4 is for avehicle wheel bearing 100 including a vehicle-wheel-bearing shaft 90, avehicle-wheel-bearing outer race assembly 102, and an inboard seal 120.The shaft 90 has an inner race 106 and 108. The outer race assembly 102includes an outer race 110 and 112 and is disposed radially outwardlyapart from the shaft 90 creating a bearing cavity 114, wherein thebearing cavity 114 has a substantially-circular inboard opening 122. Theinboard seal 120 has a member 124 attached to the outer race assembly102, wherein the member 124 has a first portion 126 substantiallycovering the inboard opening 122 and has a second portion 128 extendingradially outwardly of the outer race assembly 102, and wherein thesecond portion 128 defines a target ring 130 for ananti-lock-braking-system (ABS) speed sensor 132. Having an inboard sealextend outside the bearing cavity to also function as a target ring foran ABS speed sensor integrates sealing and target ring features into asingle member reducing costs.

In one example of the second embodiment shown in FIG. 4, the vehiclewheel bearing assembly 88 also includes wheel studs 134, and balls 136and 138, as shown, wherein the inboard inner race 106 is shown as aseparate member and not as a monolithic portion of the shaft 90. In oneconstruction, the inboard seal 120 also has another member 140 attachedto the inboard inner race 106, wherein both members 124 and 140, withinthe bearing cavity 114, comprise stainless steel with elastomer lips.

A third embodiment of the invention is shown in FIG. 5. A firstexpression of the third embodiment shown in FIG. 5 is for a vehiclewheel bearing 142 including a vehicle-wheel-bearing non-rotatable shaft144, a vehicle-wheel-bearing rotatable outer race assembly 146, ananti-lock-braking-system (ABS) speed sensor 148, and a target ring 150.The shaft 144 has an inner race 152 and 154. The outer race assembly 146has an outer race 156 and 158 and is disposed radially outwardly apartfrom the shaft 144 creating a bearing cavity 160, wherein the bearingcavity 160 has a substantially-circular outboard opening 162. The ABSspeed sensor 148 is disposed in the bearing cavity 160 and is attachedto the shaft 144 proximate the outboard opening 162. The target ring 150is disposed in the bearing cavity 160, is attached to the outer raceassembly 146, and has a portion 164 disposed to be sensed by the ABSspeed sensor 148.

In one example of the first expression of the third embodiment, theshaft 144 has a central bore 166 having an outboard end 168 and aninboard end 170. A wire connector 172 is disposed at the inboard end170, and wiring 174 is disposed in the central bore 166 and connects theABS speed sensor 148 and the wire connector 172. In the same or adifferent example, an end cap 176 is attached to the outer race assembly146 and covers the outboard opening 162 of the bearing cavity 160 andthe outboard end 168 of the central bore 166. In the same or anotherexample, the target ring 150 is an extension of the end cap 176. Theorientation of the target ring 150 and the ABS speed sensor 148 is leftto the artisan. Having an ABS speed sensor positioned in the bearingcavity and attached to the shaft proximate the outboard opening of thecavity and having the target ring positioned in the bearing cavity andattached to the outer race assembly places the ABS speed sensor andtarget ring inside the bearing where an existing bearing seal or end capoffers protection from the wheel environment without the need for aseparate seal for the ABS speed sensor and target ring. In oneconstruction, the vehicle wheel bearing 142 also includes balls 178 and180 and an inboard seal 182. In one modification, the shaft 144 isattached to a vehicle knuckle member 184, and wheel studs 186 areattached to the uter race assembly 146.

It is noted that the previously-described examples, constructions,implementations, designs, modifications, variations, and depictions ofany expression of an embodiment can be combined, as appropriate, in thatexpression and/or can be used, as appropriate, in any other embodiment,as can be appreciated by the artisan.

The foregoing description of a several expressions and embodiments ofthe invention has been presented for purposes of illustration. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed, and obviously many modifications and variations are possiblein light of the above teaching. It is intended that the scope of theinvention be defined by the claims appended hereto.

1. A vehicle wheel bearing assembly comprising: a) a vehicle knucklemember which has a bore, which has a substantially-outboard-facingsurface and a substantially-inboard-facing surface; and b) a vehiclewheel bearing having: (1) a monolithic, non-rotatable shaft whichincludes an outboard inner race and a shoulder, wherein the shaft isdisposed in the bore, wherein the shoulder abuts thesubstantially-outboard-facing surface, and wherein the shaft is attachedto the vehicle knuckle member against the substantially-inboard-facingsurface; (2) an inboard inner race; and (3) a monolithic, rotatableouter race assembly which surrounds the shaft and which includes anoutboard outer race defining an inboard raceway with an outboard innerrace and containing balls therebetween and an inboard outer racedefining an inboard raceway with inboard inner race and containing ballstherebetween, and an inboard seal located radially between the shaft andouter race assembly.